Injection molding system with improved pressure bushing

ABSTRACT

A molding system including an injection molding machine, particularly an electric injection molding machine, with an extrusion nozzle coupled to a hot tip system by an improved pressure bushing. The pressure bushing has a passage therethrough with an inlet and an extrusion nozzle seating surface disposed thereabout on an inlet side of the pressure bushing. The pressure bushing passage includes an outlet coupled to the hot tip system. The pressure bushing passage has a relatively reduced diameter and a reduced axial dimension that eliminate or at least substantially reduce ejecta from the coupling between an extrusion nozzle of the molding machine and the pressure bushing without freeze-out.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.09/028,379, now U.S. Pat. No. 5,993,190 entitled "Injection MoldingSystem With Improved Pressure Bushing", filed on Feb. 24, 1998, which isincorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention relates generally to injection molding systems, and moreparticularly to improved pressure bushings for coupling molten materialsextrusion nozzles to hot tip systems and combinations thereof.

Hot tip systems are known and include generally one or more heated tipsfor supplying molten materials, usually molten plastics, tocorresponding mold cavities. to Exemplary hot tip systems include theHPS Single and Multi-Tip Nozzle Standard and Special Systems, Types 97,98 and 99, available from Ewikon N.A. Inc., Elgin, Ill. The moltenmaterial is supplied to the hot tip system by an extrusion nozzle of aninjection molding machine. More particularly, the hot tip system,including the mold, is mounted and clamped in the injection moldingmachine between fixed and movable platens thereof. The extrusion nozzleis coupled to the hot tip system by a pressure bushing, which is mountedor otherwise securely fastened to the hot tip system. In operation, theextrusion nozzle is advanced toward and biased into seated engagementwith the pressure bushing as molten material is supplied therefrom underpressure to the hot tip system. The force exerted by the extrusionnozzle on the pressure bushing varies depending on the type and ratedclamping tonnage of the injection molding machine. The pressure at whichthe molten material is supplied from the extrusion nozzle to the hotrunner system depends on the injection molding machine and hot tipsystem configurations.

In the past, injection molding machines were operated hydraulically,including operation of the movable platen, advancement and retraction ofthe extrusion nozzle, and extrusion of molten material therefrom. Morerecently, the hydraulic injection molding machines are being replaced inmany applications by electric injection molding machines, which haveseveral advantages over the hydraulic machines. Electric injectionmolding machines have, for example, substantially reduced powerconsumption and other operational cost savings some of which result fromthe elimination of hydraulic components. Electric machines are also notsusceptible to drift, which plagues hydraulic machines, and providegenerally more precise control over fluid pressure regulation and othersystems operations, thereby providing more consistent moldingperformance and improved productivity.

Most hot tip systems were designed originally for use with hydraulicmachines, and when used with electric machines have a tendency to ejectmolten material at high pressure from between the extrusion nozzle andthe pressure bushing, a phenomenon referred to sometimes as blowback.Besides the obvious safety hazard blowback poses to personnel, it alsoadversely affects the supply of molten material to the hot tip systemand the mold cavities by diverting the molten material supply andreducing supply pressure, thereby resulting in inconsistent moldingperformance.

Blowback of ejecta was not a significant problem with hydraulicinjection molding machines because, in comparison to electric machines,hydraulic machines exert a relatively high force to bias the extrusionnozzle into seated engagement with the pressure bushing as moltenmaterial is supplied therefrom to the hot tip system.

The present invention is drawn toward advancements in the art ofinjection molding systems, and more particularly to novel pressurebushings for coupling injection molding machines to hot tip systems andcombinations thereof.

The inventors of the present invention recognized that molten materialejecta may be eliminated or at least substantially reduced byappropriately modifying the pressure bushing by generally reducing thesize of the molten material passage therethrough. The pressure bushingof the HPS Single and Multi-Tip Nozzle Standard and Special Systemsdiscussed above, for example, have a passage diameter of approximately0.475 inches and an axial dimension of approximately 0.125 inches. Otherknown pressure bushings have passage diameters of approximately 0.250inches. These prior art pressure bushings, and more particularly thedimensions of the molten material passages therethrough, were designedfor hydraulic molding machines, and when used with electric machinesexhibit blowback of ejecta, which is undesirable.

Hot tip manufacturers and others have expressed mistaken concerns thatreducing the size of the pressure bushing passage would unduly increasemolten material supply pressure, and would give rise to an excessivepressure drop in the hot tip system, thereby adversely affecting moldingperformance. It was also believed, incorrectly, that molten material inthe pressure bushing passage would have a tendency to form a hardenedplug, a phenomenon referred to sometimes as freeze-off, especially uponcessation of the molten material supply and upon retraction of theextrusion nozzle away from the pressure bushing, and that the hardenedplug would obstruct the supply of molten material to the tips of the hottip system and possibly damage an internal heater tube thereof uponre-establishing the molten material supply. These concerns howeverproved erroneous.

It is an object of the invention to provide novel injection moldingsystems that overcome problems in the prior art, and novel injectionmolding systems that are economical to manufacture and operate.

It is also an object of the invention to provide novel injection moldingsystems that provide more consistent molding performance.

It is another object of the invention to provide novel injection moldingsystems that eliminate or at least substantially reduce blowback ofejecta from a coupling between injection molding machines, particularlyelectric injection molding machines, and hot tip systems.

It is a further object of the invention to provide novel injectionmolding systems with improved pressure bushings for coupling injectionmolding machines and hot tip systems, and improved pressure bushingsthat are retrofittable in existing injection molding systems.

A more particular object of the invention is to provide novel injectionmolding systems including an injection molding machine, especially anelectric injection molding machine, coupleable to a hot tip systemhaving an improved pressure bushing with a generally reduced moltenmaterial passage therethrough that eliminates or at least substantiallyreduces ejecta from the coupling between an extrusion nozzle of themolding machine and the pressure bushing without freeze-out.

These and other objects, aspects, features and advantages of the presentinvention will become more fully apparent upon careful consideration ofthe following Detailed Description of the Invention and the accompanyingDrawings, which may be disproportionate for ease of understanding,wherein like structure and steps are referenced generally bycorresponding numerals and indicators.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial sectional view of a hot tip system with a prior artpressure bushing coupled to an injection molding machine.

FIG. 2 is a top plan view of an improved pressure bushing according toan exemplary embodiment of, the present invention.

FIG. 3 is a sectional view along lines a--a of the improved pressurebushing of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an injection molding system comprising generally aninjection molding machine 20, shown in part, having a molten materialextrusion nozzle 30 for supplying molten material therefrom to a hot tipsystem 40 having one or more tips 42 for supplying molten material tocorresponding mold cavities 44.

The injection molding machine 20 in the exemplary embodiment ispreferably an electric injection molding machine, for example, one ofthe Roboshot™ all electric machines, Model Nos. 17R and 33R, availablefrom Cincinnati Milacron™, Plastics Machinery Group, Batavia, Ohio.These exemplary electric injection molding machines supply moltenmaterial from an outlet 32 of the extrusion nozzle 30 to the hot tipsystem 40 at pressures up to approximately 34,000 psi depending on theinjection molding machine and hot tip system configurations. Theinvention is applicable more generally to hot tip systems coupled to anyelectric or hydraulic injection molding machine supplying fluids at notmore than approximately 34,000 psi.

FIG. 1 illustrates the hot tip system 40 including generally a moltenmaterial inlet 46, which is coupleable to the extrusion nozzle outlet 32of the injection molding machine 20 as discussed further below, forsupplying molten material to the one or more tips 42. The hot tip system40 also includes an internal heater element controlled by a thermocoupleas is known generally. The hot tip system 40 of the exemplary embodimentis a thermocouple controlled, multiple HPS Hot Tip system available fromEwikon N.A. Incorporated, Elgin, Ill., although the invention is moregenerally applicable to any of the HPS Single or Multi-Tip NozzleStandard and Special Systems, Types 97, 98 and 99 available from EwikonN.A. Inc. as discussed above, among other systems.

The system of FIG. 1 illustrates the hot tip system 40 including also apressure bushing 50 fixedly mounted thereto, for example, by a locatingring 60 fastened to the hot tip system 40, whereby the prior artpressure bushing 50 is clamped between the locating ring 60 and the hottip system 40. The prior art pressure bushing 50 includes generally anopening, or passage, 52 therethrough, having a relatively large diameterand a relatively long axial dimension as discussed in the Background ofthe Invention. The prior art pressure bushing 50 includes an inlet 54 onan inlet end thereof and a contoured seating surface 55 disposed aboutthe inlet 54 for accommodating an end portion 34 of the extrusion nozzle30. The prior art pressure bushing also includes an outlet 56 coupled tothe hot tip system molten material inlet.

The extrusion nozzle end portion 34 is biasable into seated engagementwith the contoured seating surface 55 disposed about the inlet 54 of thepressure bushing 50 with a force that depends on the type and ratedtonnage of the particular injection molding machine 20 as discussedfurther below. The exemplary Roboshot™ all electric machines, Model Nos.17R and 33R available from Cincinnati Milacron™, discussed above exertthe extrusion nozzle 30 into seated engagement with the pressure bushing50 with forces of approximately 0.77 tons and 0.88 tons, respectively.The pressure bushing of the present invention is more generallyapplicable for coupling hot tip systems to any hydraulic or electricinjection molding machine that seats the extrusion nozzle 30 intoengagement with the pressure bushing 50 with a force not less thanapproximately 0.77 tons.

FIGS. 2 and 3 illustrate a pressure bushing 150 according to the presentinvention having a molten material opening, or passage, 152therethrough. The pressure bushing passage 152 includes an inlet 154with a contoured seating surface 155 thereabout on an inlet side of thepressure bushing for accommodating the end portion 34 of the extrusionnozzle 30, as illustrated in FIG. 1. The pressure bushing passage 152also includes an outlet 156 on an outlet side thereof, wherein theoutlet is coupled to the hot tip system molten material inlet 46, asdiscussed above in connection with FIG. 1.

The diameter of the pressure bushing passage is dependent generally onthe molten material supply pressure and the force with which the endportion 34 of the extrusion nozzle 30 is biased into seated engagementwith the seating surface 155 of the pressure bushing. Generally,decreasing the molten material supply pressure and or increasing theforce with which the extrusion nozzle is biased into engagement with thepressure bushing permits increasing the pressure bushing passagediameter without blowback of ejecta. Blowback will occur if the diameterof the pressure bushing passage is too great. Freeze-off of the moltenmaterial becomes a more likely possibility if the diameter of thepressure bushing passage is too narrow. In most applications, it isgenerally desirable to maximize the diameter of the pressure bushingpassage, without permitting blowback, to increase the molten materialsupply rate to the hot tip system, thereby lessening the likelihood offreeze-off and increasing productivity.

In one application, the extrusion nozzle 30 supplies molten material ata pressure not exceeding approximately 34,000 psi and the end portion 34of the extrusion nozzle is biased into seated engagement with thepressure bushing seating surface 155 with a force not less thanapproximately 0.77 tons, which is typical of the exemplary 17 tonRoboshot™ electric molding machine, Model No. 17R, discussed above. Forthis application, the diameter of the pressure bushing passage 152 is ina range between approximately 0.125 inches and approximately 0.196inches, and in a preferred embodiment the diameter of the passage isapproximately 0.196 inches.

In another application, the extrusion nozzle 30 supplies molten materialat a pressure not exceeding approximately 34,000 psi and the end portion34 of the extrusion nozzle 30 is biased into seated engagement with thepressure bushing seating surface 155 with a force not less thanapproximately 0.88 tons, which is typical of the exemplary 33 tonRoboshot™ electric molding machine, Model No. 33R, discussed above. Forthis alternative application, the diameter of the pressure bushingpassage 152 is also in a range between approximately 0.125 inches andapproximately 0.196 inches, with a preferred passage diameter ofapproximately 0.196 inches.

FIG. 3 illustrates the passage 152 of the pressure bushing 150 having anaxial dimension AD. Generally, reducing the axial dimension of thepassage 152 decreases the likelihood of freeze-off, particularly for therelatively narrow pressure bushing passage diameter range of the presentinvention. The structural integrity of the pressure bushing may becompromised however if the axial dimension AD of the passage is reducedwithout restraint, resulting in failure and possibly damage to thepressure bushing. The axial dimension of the pressure bushing passagealso depends on the radius of the extrusion nozzle end portion 34.

In an exemplary embodiment, the axial dimension of the passage 152 is ina range between approximately 0.032 inches and approximately 0.100inches. A pressure bushing passage having this exemplary axial dimensionpreferably accommodates an extrusion nozzle end portion 34 having aradius of approximately 0.75 inches. In a preferred embodiment, the endportion of the extrusion nozzle has a radius of approximately 0.75inches, and the passage of the pressure bushing has an axial dimensionof approximately 0.100 inches.

These exemplary pressure bushing axial dimensions are used preferablywith a pressure bushing having a diameter in a range betweenapproximately 0.125 inches and approximately 0.196 inches, wherein theinjection molding machine supplies fluid at not more than approximately34,000 psi and the extrusion nozzle 30 is seated into engagement withthe pressure bushing 50 with a force not less than approximately 0.77tons as discussed above.

While the foregoing written description of the invention enables one ofordinary skill in the art to make and use what is at present consideredto be the best mode of the invention, it will be appreciated andunderstood by those of ordinary skill the existence of variations,combinations, modifications and equivalents within the spirit and scopeof the specific exemplary embodiments disclosed herein. The presentinvention is therefore to be limited not by the specific exemplaryembodiments disclosed herein but by all embodiments within the scope ofthe appended claims.

What is claimed is:
 1. An electric injection molding systemcomprising:an electric injection molding machine; a single hot tipsystem having a molten material inlet; a pressure bushing having amolten material passage therethrough, the passage of the pressurebushing having an inlet on an inlet side of the pressure bushing and anoutlet on an outlet side of the pressure bushing, the outlet side of thepressure bushing coupled to the molten material inlet of the hot tipsystem, and the electric injection molding machine directly connectableto the hot tip system by the pressure bushing.
 2. The system of claim 1,the passage of the pressure bushing having a diameter in a range betweenapproximately 0.125 inches and approximately 0.196 inches, the pressurebushing having an axial dimension in a range between approximately 0.032inches and approximately 0.100 inches.
 3. The system of claim 2, theinjection molding machine is a 17 ton electric injection molding machinehaving an extrusion nozzle with an end portion that is biasable intoengagement with the inlet side of the pressure bushing with a force ofapproximately 0.77 tons.
 4. The system of claim 2, the injection moldingmachine is a 33 ton electric injection molding machine having anextrusion nozzle with an end portion that is biasable into engagementwith the pressure bushing with a force of approximately 0.88 tons.
 5. Anelectric injection molding system comprising:a mold cavity; an electricinjection molding machine having a material extrusion nozzle with an endportion from which molten material is supplied; a hot tip system havinga molten material inlet and a tip with a molten material outlet coupledto the mold cavity; a pressure bushing having a molten material passagetherethrough, the passage of the pressure bushing having an inlet on aninlet side of the pressure bushing and an outlet on an outlet side ofthe pressure bushing, the outlet side of the pressure bushing coupleddirectly to the molten material inlet of the hot tip system, and theextrusion nozzle of the electric injection molding machine directlyconnectable to the inlet side of the pressure bushing.
 6. The system ofclaim 5, a plurality of mold cavities, the hot tip system having aplurality of tips each having a molten material outlet coupled to acorresponding one of the plurality of mold cavities.
 7. The system ofclaim 5, the mold cavity and hot tip system mounted between fixed andmovable platens of the injection molding machine.
 8. The system of claim5, the passage of the pressure bushing having a diameter in a rangebetween approximately 0.125 inches and approximately 0.196 inches, thepressure bushing having an axial dimension in a range betweenapproximately 0.032 inches and approximately 0.100 inches.
 9. The systemof claim 8, the injection molding machine is a 17 ton electric injectionmolding machine, the end portion of the extrusion nozzle is biasableinto engagement with the inlet side of the pressure bushing with a forceof approximately 0.77 tons.
 10. The system of claim 8, the injectionmolding machine is a 33 ton electric injection molding machine, the endportion of the extrusion nozzle is biasable into engagement with thepressure bushing with a force of approximately 0.88 tons.
 11. Anelectric injection molding system comprising:an electric injectionmolding machine having fixed and movable platens, and a materialextrusion nozzle with an end portion from which molten material issupplied; a single hot tip system mounted between the fixed and movableplatens of the electric injection molding machine, the hot tip systemhaving a molten material inlet; a pressure bushing having a moltenmaterial passage therethrough, the passage of the pressure bushinghaving an inlet on an inlet side of the pressure bushing and an outleton an outlet side of the pressure bushing, the outlet side of thepressure bushing directly coupled to the molten material inlet of thehot tip system, and the extrusion nozzle of the electric injectionmolding machine directly connectable to the inlet side of the pressurebushing.
 12. The system of claim 11, a mold cavity coupled to an outletof the hot tip system.
 13. The system of claim 11, the passage of thepressure bushing having a diameter in a range between approximately0.125 inches and approximately 0.196 inches, the pressure bushing havingan axial dimension in a range between approximately 0.032 inches andapproximately 0.100 inches.
 14. The system of claim 13, the injectionmolding machine is a 17 ton electric injection molding machine, the endportion of the extrusion nozzle is biasable into engagement with theinlet side of the pressure bushing with a force of approximately 0.77tons.
 15. The system of claim 13, the injection molding machine is a 33ton electric injection molding machine, the end portion of the extrusionnozzle is biasable into engagement with the pressure bushing with aforce of approximately 0.88 tons.
 16. An injection molding systemcomprising:an injection molding machine; a hot tip system having amolten material inlet; a pressure bushing having a molten materialpassage therethrough, the passage of the pressure bushing having aninlet on an inlet side of the pressure bushing and an outlet on anoutlet side of the pressure bushing, the passage of the pressure bushinghaving a diameter in a range between approximately 0.125 inches andapproximately 0.196 inches, the pressure bushing having an axialdimension in a range between approximately 0.032 inches andapproximately 0.100 inches, the outlet side of the pressure bushingcoupled to the molten material inlet of the hot tip system, and theinjection molding machine directly coupled to the inlet side of thepressure bushing.
 17. The system of claim 16, the injection moldingmachine is a 17 ton electric injection molding machine having anextrusion nozzle with an end portion that is biasable into engagementwith the inlet side of the pressure bushing with a force ofapproximately 0.77 tons.
 18. The system of claim 16, the injectionmolding machine is a 33 ton electric injection molding machine having anextrusion nozzle with an end portion that is biasable into engagementwith the pressure bushing with a force of approximately 0.88 tons. 19.An injection molding system comprising:a mold cavity; an injectionmolding machine having a material extrusion nozzle with an end portionfrom which molten material is supplied; a hot tip system having a moltenmaterial inlet and a tip with a molten material outlet coupled to themold cavity; a pressure bushing having a molten material passagetherethrough, the passage of the pressure bushing having an inlet on aninlet side of the pressure bushing and an outlet on an outlet side ofthe pressure bushing, the passage of the pressure bushing having adiameter in a range between approximately 0.125 inches and approximately0.196 inches, the pressure bushing having an axial dimension in a rangebetween approximately 0.032 inches and approximately 0.100 inches, theoutlet side of the pressure bushing coupled to the molten material inletof the hot tip system, and the extrusion nozzle of the injection moldingmachine coupled directly to the inlet side of the pressure bushing. 20.The system of claim 19, the injection molding machine is a 17 tonelectric injection molding machine, the end portion of the extrusionnozzle is biasable into engagement with the inlet side of the pressurebushing with a force of approximately 0.77 tons.
 21. The system of claim19, the injection molding machine is a 33 ton electric injection moldingmachine, the end portion of the extrusion nozzle is biasable intoengagement with the pressure bushing with a force of approximately 0.88tons.
 22. An injection molding system comprising:an injection moldingmachine having fixed and movable platens, and a material extrusionnozzle with an end portion from which molten material is supplied; a hottip system mounted between the fixed and movable platens of theinjection molding machine, the hot tip system having a molten materialinlet and a tip with a molten material outlet; a pressure bushing havinga molten material passage therethrough, the passage of the pressurebushing having an inlet on an inlet side of the pressure bushing and anoutlet on an outlet side of the pressure bushing, the passage of thepressure bushing having a diameter in a range between approximately0.125 inches and approximately 0.196 inches, the pressure bushing havingan axial dimension in a range between approximately 0.032 inches andapproximately 0.100 inches, the outlet side of the pressure bushingdirectly coupled to the molten material inlet of the hot tip system, andthe extrusion nozzle of the injection molding machine is directlycoupled to the inlet side of the pressure bushing to supply moltenmaterial to the hot tip system.
 23. The system of claim 22, theinjection molding machine is a 17 ton electric injection moldingmachine, the end portion of the extrusion nozzle is biasable intoengagement with the inlet side of the pressure bushing with a force ofapproximately 0.77 tons.
 24. The system of claim 22, the injectionmolding machine is a 33 ton electric injection molding machine, the endportion of the extrusion nozzle is biasable into engagement with thepressure bushing with a force of approximately 0.88 tons.